BGS technic 8320 User manual

BGS technic KG

Bandwirkerstr. 3

D-42929 Wermelskirchen

Tel.: 02196 720480

Fax.: 02196 7204820

mail@bgs-technic.de

www.bgstechnic.com

BGS 8320

Duplex Clutch Repair Kit for

VAG DSG Transmissions

TOOLS

1 Thrust piece,

to be used as OEM T10376

2 Slip gauge,

to be used as OEM T10374

3 Puller,

to be used as OEM T10373

4 Support bridge,

to be used as OEM T10323

INTENDED USE

This repair kit is needed for servicing clutches in the following car types:

VW Golf (since 2004), Golf Plus (since 2005) with 7-drive transmission (Code 0AM), Audi A3 (since

2004) with 7-drive transmission (Code 0AM) and Touareg (since 2003) with 6-drive transmission

(Code 08D).

SAFETY INFORMATIONS

•Do not use the tool if parts are missing or damaged.

•Use the tool for the intended purpose only.

•Never place the tool on the vehicle battery. There is a risk of a short circuit.

•Be careful when working with the engine running. Loose clothing, tools and other objects can

be caught by rotating parts and cause serious injury.

•Keep children and other unauthorized persons away from the work area.

•Do not allow children to play with the tool or its packaging.

•Be careful when working on hot engines because of the risk of burn injuries.

•If you remove the ignition key before repairing, you can prevent the engine from being started

accidentally and resulting in engine damage.

•This manual serves as a brief guide and does not replace a workshop manual. Always refer to

the vehicle-specific service literature, particularly the technical data such as torque values and

instructions for disassembly/assembly, etc..

BGS technic KG

Bandwirkerstr. 3

D-42929 Wermelskirchen

Tel.: 02196 720480

Fax.: 02196 7204820

mail@bgs-technic.de

www.bgstechnic.com

INSTRUCTION

Support bridge

Remove clutch hub.

Disassemble lock ring of the clutch (this might be difficult

because the clutch is under strong tension

Release the clutch by using the support bridge as shown in

the picture.

Puller

After the disassembly of the lock ring you can attach the

puller as shown and disassemble the clutch by turning the

puller spindle.

Slip gauge

You can adjust the position of the engaging bearings by

using the slip gauge. Use a depth gauge for measuring. For

exact dimensions and detailed information about how to do

it, consult the manufacturer’s handbook.

ADJUSTMENT

Adjust position of the engaging bearings.

It is necessary to adjust the position of the engaging bearings after replacing the engaging bearings,

the starting lever or the starting lever seating.

The locating face (gearbox/motor) has to be completely level in order to make sure for a good rest for

the ruler.

BGS technic KG

Bandwirkerstr. 3

D-42929 Wermelskirchen

Tel.: 02196 720480

Fax.: 02196 7204820

mail@bgs-technic.de

www.bgstechnic.com

Installation of the two starting levers

and their engaging bearings.

Place the 1.4 millimeter thick dial on each

bearing (arrow).

As there are 2 clutches, there will be 2 steps of adjusting

them.

You will be doing several measurements while carrying out

this operation.

Each measurement requires different preparations and a few

simple calculations.

Please strictly follow these operating sequences.

You will start with the big engaging bearing for clutch 1 (K1).

First measurement for (K1)

Remove the small engaging bearing with the 1.4 millimeter

thick dial.

Place the slip gauge on the big engaging bearing.

Exert some pressure on the slip gauge and rotate it to make

sure for the correct seating of the slip gauge on the bearing.

Place the ruler on the gearbox flange and use the depth

gauge for your measurement of the depth down to the gear

shaft.

Note down the measured value as (B).

Example: B= 62.3 mm

Slip gauge

BGS technic KG

Bandwirkerstr. 3

D-42929 Wermelskirchen

Tel.: 02196 720480

Fax.: 02196 7204820

mail@bgs-technic.de

www.bgstechnic.com

Second measurement for (K1)

Measure the distance from the ruler down to the slip gauge.

Make this measurement as precisely as possible by taking

readings from two opposite positions.

Thus, the determined value will be more precise, and any

inaccuracy caused by a „tilting“ on the engaging bearing will

be minimized.

Take the mean value of both measurements on the slip

gauge. Note down the value as (A).

Example: A= 64 mm

Calculate the difference of the 2 values

A - B = ?

In our example the calculation is as follows:

64.0 mm – 62.3 mm = 1.7 mm

Refer to the below table for the required thickness of the dial.

Your reading for bearing K1

from

required dial

0,71 mm

0,9 mm

0,8 mm

0,91 mm

1,1 mm

1,0 mm

1,11 mm

1,3 mm

1,2 mm

1,31 mm

1,5 mm

1,4 mm

1,51 mm

1,7 mm

1,6 mm

1,71 mm

1,9 mm

1,8 mm

1,91 mm

2,1 mm

2,0 mm

2,11 mm

2,3 mm

2,2 mm

2,31 mm

2,5 mm

2,4 mm

2,51 mm

2,7 mm

2,6 mm

2,71 mm

2,9 mm

2,8 mm

In our example we need a 1.6 mm thick dial.

Never use more than a single dial. Never place 2 dials on top of each other to reach the required

thickness.

Following this procedure, the position of the bearing K1 will be adjusted.

Remove again the bigger starting lever for the subsequent

(K2) measurement.

Slip gauge

BGS technic KG

Bandwirkerstr. 3

D-42929 Wermelskirchen

Tel.: 02196 720480

Fax.: 02196 7204820

mail@bgs-technic.de

www.bgstechnic.com

First measurement for (K2)

Use a 1.4 mm thick dial.

Install the small bearing only with a 1.4 mm thick dial.

The small engaging bearing will only lock into one position

because of the 4 grooves.

Rotate to check that the bearing is correctly installed with the

grooves in their right position.

Place the slip gauge onto the small bearing.

Slip gauge

BGS technic KG

Bandwirkerstr. 3

D-42929 Wermelskirchen

Tel.: 02196 720480

Fax.: 02196 7204820

mail@bgs-technic.de

www.bgstechnic.com

Use the depth gauge to measure down to the gear shaft.

Note down this value as (B).

Example: B = 62.3 millimeters

Second measurement for (K2)

Measure the distance from the ruler down to the slip gauge.

Make this measurement as precisely as possible by taking

readings from two opposite positions.

Thus, the determined value will be more precise, and any

inaccuracy caused by a „tilting“ on the engaging bearing will

be minimized.

Take the mean value of both measurements on the slip

gauge. Note down the value as (A).

Example: A= 63.5 mm

Calculate the difference of the 2 values

A - B = ?

In our example the calculation is as follows:

63.5 mm – 62.3 mm = 1.2 mm

Refer to the below table for the required thickness of the dial.

Your reading for the bearing K2

from

required dial

0,71 mm

0,9 mm

0,8 mm

0,91 mm

1,1 mm

1,0 mm

1,11 mm

1,3 mm

1,2 mm

1,31 mm

1,5 mm

1,4 mm

1,51 mm

1,7 mm

1,6 mm

1,71 mm

1,9 mm

1,8 mm

1,91 mm

2,1 mm

2,0 mm

2,11 mm

2,3 mm

2,2 mm

2,31 mm

2,5 mm

2,4 mm

2,51 mm

2,7 mm

2,6 mm

2,71 mm

2,9 mm

2,8 mm

In our example we need a 1.2 mm thick dial.

Never use more than a single dial. Never place 2 dials on top of each other to reach the required

thickness.

Following this procedure, the position of the bearing K2 will be adjusted.

Slip gauge

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